Design for Additive Manufacturing (DfAM), Second Cycle, 7.5 credits

Learning outcomes

After completing the course, the student should

- have a general knowledge of some of the most common manufacturing methods within AM,
- have basic knowledge of design rules for AM,
- have knowledge of CAE methodology for AM,
- have knowledge of common materials for AM,
- have knowledge of dimensioning with common AM materials,
- have knowledge of lattice structures suitable for AM,
- have knowledge in modeling conformal cooling channels and heat exchangers,
- have knowledge of lightweight design with topology optimization and AM,
- have knowledge of implicit-based geometry modeling, and
- have knowledge of residual stresses in AM.

Competence and skills
After completing the course, the student should be able to

- independently design lightweight solutions with topology optimization and lattice structures,
- design conformal cooling channels and heat exchangers for AM,
- independently dimension mechanical designs in standard AM materials, and
- independently simulate residual stresses in AM.

Judgement and approach
After completing the course, the student must have the ability to

- determine if a design is suitable for AM,
- be able to design lightweight, conformal cooling channels and heat exchangers for AM, and
- be able to predict risks with residual stresses in AM through simulation.

Content

The following topics are covered

- the basic principles of FDM, SLS, SLM and EBM,
- basic design principles, for example overhang angles, holes, thin parts, support structures,
- mechanical properties of standard materials, for example PLA, PA11, PEEK, AlSi10Mg, 316L, Ti6Al4V,
- strut-based and TPMS-based lattices (eg the Gyroid structure),
- design principles for conformal cooling channels and heat exchangers,
- topology optimization with SIMP,
- CAE steps from design domain to sliced stl file,
- dimensioning with FEM,
- modeling and simulation of residual stresses, and
- 3D printing of mechanical designs.

Examinations and grades

Theory, 1.5 credits (Code: A001)
Grades used are Fail (U) or Pass (G).

Project Task, 6 credits (Code: A002)
Grades used are Fail (F), Sufficient (E), Satisfactory (D), Good (C), Very Good (B) or Excellent (A).

According to the Higher Education Ordinance, Chapter 6, Section 18, a grade is to be awarded on the completion of a course, unless otherwise prescribed by the university. The university may determine which grading system is to be used. The grade must be determined by a teacher specifically nominated by the university (the examiner).

In accordance with university regulations on grading systems for first and second-cycle courses and study programmes (Vice-Chancellor’s decision ORU 2018/00929), one of the following grades is to be used: fail (U), pass (G) or pass with distinction (VG). For courses included in an international master’s programme (60 or 120 credits) or offered to the university’s incoming exchange students, the A to F grading scale is to be used. The vice-chancellor, or a person appointed by them, may decide on exceptions from this provision for a specific course, if there are special grounds for doing so.

The grades used on this course are Fail (F), Sufficient (E), Satisfactory (D), Good (C), Very Good (B) or Excellent (A).

Comments on grades

Grades for the entire course are determined by exam code A002, provided that exam code A001 is passed.

Modes of assessment

Theory (code A001): Written exam. The re-exam falls within eleven weeks of the regular exam.

Project task (code A002): Written submission task and oral examination. In the event of absence from a mandatory training session, the examiner decides whether the session can be taken again at another teaching session of the same type. Otherwise, the student is referred to the next course opportunity.

For students with a documented disability, the university may approve applications for adapted or other modes of assessment.

For further information, see the university's local examination regulations.

Specific entry requirements

Mechanics 7.5 Credits, Strength of materials 7.5 Credits and 15 Credits in Mathematics (including at least 4.5 Credits Linear algebra and 4.5 Credits Calculus). The applicant must also have qualifications corresponding to the course "English 6" or "English B" from the Swedish Upper Secondary School.

For further information, see the university's admission regulations.

Other provisions

Students who have been admitted to and registered on a course have the right to receive tuition and/or supervision for the duration of the time period specified for the particular course to which they were accepted (see, the university's admission regulations (in Swedish)). After that, the right to receive tuition and/or supervision expires.

Reading list and other learning resources

Olaf Diegel, Axel Nordin, Damien Motte, A Practical Guide to Design for Additive Manufacturing, Springer, 2020.
Supplement material.